US4507405A - Synthetic articles having a cork-like appearance - Google Patents

Synthetic articles having a cork-like appearance Download PDF

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Publication number
US4507405A
US4507405A US06/389,509 US38950982A US4507405A US 4507405 A US4507405 A US 4507405A US 38950982 A US38950982 A US 38950982A US 4507405 A US4507405 A US 4507405A
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United States
Prior art keywords
caramel
composition
colorant
closure
resinous material
Prior art date
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US06/389,509
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English (en)
Inventor
Gary V. Paisley
Alex Malaspina
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Coca Cola Co
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Coca Cola Co
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Assigned to COCA-COLA COMPANY, THE, A CORP. OF DE reassignment COCA-COLA COMPANY, THE, A CORP. OF DE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: MALASPINA, ALEX, PAISLEY, GARY V.
Priority to US06/389,509 priority Critical patent/US4507405A/en
Priority to US06/458,775 priority patent/US4522856A/en
Priority to IE834/83A priority patent/IE54020B1/en
Priority to NZ203931A priority patent/NZ203931A/en
Priority to CA000426157A priority patent/CA1197045A/en
Priority to DE8383103815T priority patent/DE3365407D1/de
Priority to EP83103815A priority patent/EP0097783B1/en
Priority to AU13697/83A priority patent/AU568491B2/en
Priority to DE198383103815T priority patent/DE97783T1/de
Priority to AT83103815T priority patent/ATE21523T1/de
Priority to ES521817A priority patent/ES521817A0/es
Priority to ZA832929A priority patent/ZA832929B/xx
Priority to MX197082A priority patent/MX162483A/es
Priority to IL68517A priority patent/IL68517A/xx
Priority to PT76666A priority patent/PT76666B/pt
Priority to GR71375A priority patent/GR78819B/el
Priority to KR1019830002241A priority patent/KR860001373B1/ko
Priority to YU1139/83A priority patent/YU43310B/xx
Priority to PL24227883A priority patent/PL242278A1/xx
Priority to PL1983255942A priority patent/PL144788B1/pl
Priority to RO111153A priority patent/RO88230B1/ro
Priority to JP58105086A priority patent/JPS596228A/ja
Priority to CS834368A priority patent/CS258464B2/cs
Priority to HU832154A priority patent/HU200349B/hu
Priority to BG61361A priority patent/BG46749A3/xx
Priority to MA20038A priority patent/MA19816A1/fr
Publication of US4507405A publication Critical patent/US4507405A/en
Application granted granted Critical
Priority to JP3289453A priority patent/JPH0525307A/ja
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/20—Compounding polymers with additives, e.g. colouring
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0004—Use of compounding ingredients, the chemical constitution of which is unknown, broadly defined, or irrelevant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/36—Feeding the material to be shaped
    • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
    • B29C44/42—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length using pressure difference, e.g. by injection or by vacuum
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K11/00—Use of ingredients of unknown constitution, e.g. undefined reaction products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/361—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons
    • B29C2043/3615—Forming elements, e.g. mandrels or rams or stampers or pistons or plungers or punching devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/361—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons
    • B29C2043/3615—Forming elements, e.g. mandrels or rams or stampers or pistons or plungers or punching devices
    • B29C2043/3621—Forming elements, e.g. mandrels or rams or stampers or pistons or plungers or punching devices a plurality of individual elements acting on the material in the same or diferent directions, e.g. making tubular T-joints, profiles
    • B29C2043/3623—Forming elements, e.g. mandrels or rams or stampers or pistons or plungers or punching devices a plurality of individual elements acting on the material in the same or diferent directions, e.g. making tubular T-joints, profiles coupled on a support, e.g. plate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/56—Stoppers or lids for bottles, jars, or the like, e.g. closures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/56—Stoppers or lids for bottles, jars, or the like, e.g. closures
    • B29L2031/565—Stoppers or lids for bottles, jars, or the like, e.g. closures for containers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/21—Circular sheet or circular blank
    • Y10T428/214—End closure
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249976—Voids specified as closed
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249987—With nonvoid component of specified composition
    • Y10T428/249988—Of about the same composition as, and adjacent to, the void-containing component
    • Y10T428/249989—Integrally formed skin
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/3167—Of cork

Definitions

  • the present invention relates to molded articles having the appearance of natural cork, such as closures for liquid product containers, and to methods and apparatus for making the same. More specifically, the present invention relates to the use of a particular colorant in the molding of synthetic plastic closures which gives the closures the appearance of natural cork.
  • thermoplastic material may be expanded from a granular form to assume a porous, solidified foam-like structure by the action of various propellants or agents for expanding or blowing the materials.
  • the blowing agents in accordance with normal practice, are usually gases or gas generating substances that have been dissolved or otherwise intimately incorporated within the thermoplastic resinous material while it is in an unexpanded granular form.
  • thermoplastic material is attaining a foaming temperature at which it is sufficiently softened and yieldable to permit the pressure of the expanding blowing agent to expand it into the desired foam structure.
  • the resulting foamed articles will exhibit elastic properties closely resembling similar products manufactured from other natural and synthetic elastomers.
  • This flexibility and resiliency plus the presence of an essentially impermeable skin allows these same articles, if molded in the proper size and shape, to function as closures for liquid product containers by being compressed and fitted into the container opening, then being allowed to expand, filling the opening and creating a continuous seal about its perimeter. Therefore, such articles would theoretically be useful as replacements for similar closure devices manufactured of more familiar materials, such as natural cork used in containers of medicine, wine and spirits.
  • thermoplastic resinous material having a natural, cork-like appearance
  • a thermoplastic resin is injected into one or more mold cavities through a single orifice in each mold cavity which forms the material into a single and continuous elongated strand within each mold cavity.
  • the strand length builds in each mold cavity, it is contained by the cavity walls which force the single and continuous elongated strand to collect in a random fashion when the strand meets resistance within the mold cavity and contacts itself at various points along its length.
  • the expansion of the blowing agent causes the randomly positioned loops of the strand to expand and coalesce leaving grain lines in the surface of the molded article similar to those found in the surface of extruded articles manufactured in accordance with previously known teachings but which, in distinction, are not straight or parallel but of varying direction, occasionally intersecting, and which are formed from a single and continuous elongated strand of resin.
  • these articles contain the randomly oriented grain lines on the entire outer surface, including the ends thereof, and thus constitutes an improvement over articles manufactured by extrusion that normally do not contain randomly oriented grain lines on the ends of the articles.
  • the retarding of the expansion of the thermoplastic material is achieved through temporary pressurization of the mold cavity which is achieved by rapidly injecting at high pressure, an expandable thermoplastic resinous material into said mold cavity and gradually removing a portion of the air displaced by said injected thermoplastic resinous material through controlled minimum venting of the mold cavity and expanding the coiled resinous material in a controlled manner through a continuation of the minimum venting to fill the mold cavity.
  • Resistance to wrinkling during subsequent compression of the article is improved to a satisfactory level by incorporating into the molding method a specific technique and series of embodiments to the molding equipment which, together, eliminate the tendency of the foaming material to form large void spaces between the dense outer skin and the foamed interior of the article. This is accomplished by insuring that all the resin material to be utilized in each article enters the mold cavity, and that each cavity entrance is positively sealed prior to the expansion of the resin, to form a solidified outer skin adjacent to the cavity wall.
  • Chronological separation of injection and expansion steps is achieved by several embodiments to the improved molding technique and equipment, including:
  • each shutoff in its associated cavity as a means of initiating and terminating the injection of material into each cavity such that the period for transfer of material to or from each mold cavity through its respective injection orifice can be positively controlled.
  • the entrance orifice is immediately sealed after the thermoplastic resinous material has been injected into the cavity to stop any further flow of the resinous material, with the cavity and also the entrance orifice being kept in a sealed condition until the resinous material subsequently expands and solidifies to form the closure.
  • the closure thus formed has a liquid impervious outer skin and a foamed inner core with no appreciable void spaces or separations between the outer skin and the foamed inner core into which said outer skin could collapse when compressed.
  • a blend of pigments were utilized to impart a cork-like appearance to the products.
  • at least 5 percent of the pigment utilized is noted as being a blend of FD&C certified alumina lake powders having a particle size of 40 to 60 microns.
  • the total pigment blend was said to comprise approximately 0.5 percent by weight of the raw material formulation used in the process.
  • colorants do not possess universal governmental acceptability and are also a relatively expensive portion of the final product.
  • an object of the present invention is to provide a molded article having a cork-like appearance.
  • a further object of the present invention is to provide a synthetic cork closure product having an improved cork-like appearance.
  • Another object of the present invention is to provide a new and improved colorant for a synthetic cork closure product which imparts a color to the closure which very closely resembles the color of natural cork closures.
  • a further object of the present invention is to provide a new and improved colorant for a synthetic cork closure product which is particularly compatible in the injection molding method for making closures as described hereinbelow.
  • Still another object of the present invention is to provide a new and improved colorant for a synthetic cork closure product which possesses universal governmental acceptability.
  • a still further object of the present invention is to provide a new and improved colorant for a synthetic cork closure product which is relatively inexpensive when compared to other colorants normally used in plastic materials.
  • Yet another object of the present invention is to provide an injection molding method for making a closure made of a resinous material containing a new and improved colorant which gives the closure a cork-like appearance.
  • plastic articles having a cork-like appearance, particularly synthetic cork closure products having a natural cork-like appearance can be obtained by incorporating into the thermoplastic material used to make the synthetic cork closure an effective amount of caramel as the colorant therefor.
  • caramel colorant is already used in various alcoholic beverages and because it is readily recognized as a commonly used food additive, its presence as a colorant in a synthetic cork possesses universal governmental acceptability as a truly international product.
  • caramel is relatively inexpensive, representing approximately 4 percent of the cost of presently known and used FD&C colorants.
  • FIG. 1 is a cross-sectional view of a typical mold which could be used in an attempt to manufacture closures for liquid product containers which resemble natural cork;
  • FIG. 2 is a cross-sectional view of a mold for the manufacture of closures for liquid product containers which resemble natural cork, wherein the molded closures do not possess undesirable channels on the exterior surface thereof and are not subject to appreciable wrinkling;
  • FIG. 3 is a perspective view of one embodiment of a closure for a liquid product container
  • FIG. 4 is a perspective view of another embodiment of a closure a liquid product container
  • FIG. 5 is a perspective view of still another embodiment of a closure for a liquid product container
  • FIG. 6 is a perspective view of a closure for a liquid product container which incorporates the cork-like appearance in only a portion of the closure;
  • FIG. 7 is a cross-sectional view of a closure for a liquid product container formed from the mold of FIG. 1;
  • FIG. 8 is a cross-sectional view of a closure for a liquid product container of the improved type made in accordance with the mold of FIG. 2;
  • FIG. 9 is an enlargement of a portion of FIG. 2 showing a shutoff pin SP in a retracted position and a single strand of unexpanded resinous material being introduced into the mold cavity.
  • the basic resinous materials or blends thereof which can be utilized to make articles which are molded or otherwise formed into articles of manufacture according to the present invention include those thermoplastic resins which possess good flexibility and resiliency and which are sufficiently compatible with the caramel colorant to produce a cork-like color and whose processing temperature is not so high as to rapidly degrade the caramel colorant.
  • resinous materials with processing temperatures of less than 400° are desirable.
  • the preferred resinous materials which can be utilized to make closure products, such as synthetic cork closures according to the present invention include polyolefins or copolymers or blends thereof which are non-toxic and which possesses good flexibility and resiliency, such as for example polyethylene, polypropylene, ethylene-vinyl acetate copolymer (EVA) and the like.
  • EVA ethylene-vinyl acetate copolymer
  • an EVA copolymer having a vinyl acetate content of about 9 to 25% by weight and a melt index of about 2 to 8 has been found to be particularly effective.
  • the properties of the finished closures may be enhanced by the addition to the basic resin of small quantities of a hardness modifying additive, such as polyethylene or ionically cross-linked ethylene-methacrylic acid copolymers.
  • a hardness modifying additive such as polyethylene or ionically cross-linked ethylene-methacrylic acid copolymers.
  • the addition of such hardness modifying additives, such as polyethylene or ionically cross-linked ethylene-methacrylic acid copolymers tends to vary the hardness and strength of the finished article and can be added to the molding composition in an amount up to about 20% by weight advantageously 5 to 19% by weight, based on the total weight of the composition.
  • the total amount of resinous material that is, the basic resinous materials including the hardness modifying additive, if any, comprise up to about 99.5% by weight of the molding composition, advantageously about 99 to 99.5% by weight.
  • the caramel colorants which can be used in the molded articles of the present invention, particularly the synthetic closures of the present invention include those in either liquid or powdered form which are added to the resinous material in an amount sufficient to impart a color to the synthetic closures which very closely resembles the color of natural cork closures. Whether liquid caramel or powdered caramel is utilized depends largely upon the particular molding method. When using the injection molding method as defined in the present application, caramel in the liquid form, that is containing a high water content of say up to about 72% by weight is not desirable because of its tacky consistency which causes it to attach itself to the internal elements of the injection molding equipment where it tends to crystallize and burn.
  • Powdered caramel on the other hand, possesses a much smaller amount of water of say about 28% by weight and thus is particularly effective in the injection molding method utilized in the present application. Obviously, when using molding methods where a tacky consistency is acceptable, then the use of liquid caramel is acceptable.
  • the powdered caramel colorant which can be utilized in the present invention is of the type described in Title 21, ⁇ 73.85 of the U.S. Code of Federal Regulations.
  • the use of this particular colorant is very effective in imparting a color to the synthetic closures which very closely replicates the color of natural cork closures. Because this caramel colorant is already used in various alcoholic beverages and is readily recognized as a commonly used food additive, it already possesses universal governmental acceptability at both national and international levels.
  • caramel colorants are the commercially available powdered caramels as designated by the International Caramel Institute. These caramel colorants have been designated into four classes as follows:
  • caramel colorants can be identified as to their class based solely on their total nitrogen and total sulfur contents.
  • the type of caramel to be utilized in a preferred embodiment of the present invention is the powdered caramel falling into Class I (Caramel Color (plain)), having a spectrograph color intensity of approximately 31 ⁇ 10 3 (CP-1) and a total nitrogen content of ⁇ 0.1% by weight and a total sulfur content of ⁇ 0.1% by weight.
  • Caramel Color (plain) which is also known as spirit caramel is a class of caramel color prepared by the controlled heat treatment of carbohydrates with caustic or acid.
  • the carbohydrate raw materials are commercially available food-grade nutritive carbohydrate sweeteners which are the monomers, glucose and fructose, and/or polymers thereof.
  • the reactants may be the carbonates and hydroxides of sodium and potassium or hydrochloric, acetic, citric and sulfuric acids. Ammonia and sulfite compounds may not be used.
  • Class I, CP-1 is particularly preferred because it was found to impart a very realistic, light yellowish-brown color to the resulting products which closely resemble the color of natural cork.
  • the caramel colorant is added to the synthetic resinous material in an amount sufficient to impart to the resulting plastic closures a color which very closely resembles that of natural cork.
  • an amount of powdered caramel up to about 1% by weight, based on the total weight of the mixture to be molded, preferably about 0.25 to 1% by weight has been found to be effective in achieving the desired natural cork color, with about 0.25% by weight being particularly preferable. Since the color intensity of natural cork is known to vary widely, the amount of colorant can be correspondingly varied widely based upon the desired final color.
  • a suitable chemical blowing agent is added to the basic resin or mixture of resins to expand the resin to a desired density.
  • the preferred blowing agent is azodicarbonamide (ABFA) because of its decomposition temperature which is in the normal processing range of the EVA resin and because of its relatively high rate of gas evolution.
  • ABFA azodicarbonamide
  • other known blowing agents may be utilized without departing from the spirit and scope of the present invention.
  • the amount of blowing agent to be added is dependent upon the density distribution desired in the finished article and the processing temperature of the raw material. For example, it has been found that by minimizing the proportion of blowing agent level and/or the processing temperature, articles are produced that exhibit a less dense outer skin and a less porous inner core, thereby making the density distribution through the article more uniform, which of course, is more desirable in preventing leakage paths on the exterior surface of the molded articles.
  • An amount of blowing agent up to about 1% by weight has been found to be desirable with an amount of 0.25 to 0.75% by weight being particularly effective.
  • a number of other materials also may be added including surface lubricants, chemical blowing agent activators and ultra-violet radiation stabilizers, all of which may add slight improvements to the producibility and/or performance of the articles.
  • surface lubricants such as surface lubricants, chemical blowing agent activators and ultra-violet radiation stabilizers, all of which may add slight improvements to the producibility and/or performance of the articles.
  • powdered caramel is particularly advantageous since it can be pre-blended with other powdered materials such as the blowing agents, the surface lubricants, the activators, the stabilizers and the like to insure uniform dispersion.
  • a typically preferred blend is as follows:
  • closures 12 24 mm diameter by 1.75 inch long closures 12 of the type often utilized in standard 750 ml wine bottles, and as shown in FIGS. 3 and 4, were manufactured at processing temperatures in the range of 370°-400° F. and an injection pressure of 20,000 psig.
  • This particular closure size and resultant density distribution showed superior mechanical performance characteristics similar to natural cork closures or to other synthetic cork closures of a different density distribution.
  • Other closure styles have been manufactured using this blend of materials and have shown comparable results. These include a closure 12 having an enlarged end 12A for gripping, as shown in FIG. 5, and the shank portion 12S of a 2-piece closure as shown in FIG. 6, which is substantially attached or glued to a metal, plastic or wooden cap 13 with an adhesive.
  • the optimum mold temperature was found to be about 70°-90° F.
  • FIG. 1 One type of mold which can be utilized is depicted in FIG. 1. Because the molded article's ability to seal the container is improved by its smoothness on the surface which contacts the container, it is desirable that this surface contain no parting lines or gating blemishes. Therefore, the mold should be designed so that the parting line is along the edge of the contact surface and gating is accomplished on a surface which will not contact the container, when the closure is used in sealing the container, namely, an end of the closure being formed.
  • a mold having at least four plates which separate during the ejection sequence was required.
  • Plate A contains the sprue bushing SBU which has a means of pulling the solidified material 10 remaining in the sprue S and runner EA away from the molded article during ejection.
  • Plate X-1 is designed to strip the solidified material from the sprue bushing SBU.
  • Plate X-2 forms the top surface of the cavities and contains the runner EA and the orifice gates OG required for injection of material into the cavities C.
  • Plate B contains the cavities C, themselves.
  • the three plates X-1, X-2, and B constitute a conventional type of 3-plate injection mold.
  • the Plate A is bolted to the fixed platen (not shown) of the molding machine using the locating ring LR for alignment with a corresponding hole on the platen.
  • the ejector housing EH is then bolted to the moving platen (not shown).
  • the mold is then operated simply by travel of the moving platen which opens and closes the mold as follows: From the full shut position, which is shown, the moving platen starts pulling the mold apart, the plates sliding on four guide pins GP.
  • the mold may part originally at either parting line P1 or P2.
  • the ejector housing EH and Plate B which are bolted together plus the plate X-2, will travel away with the moving platen until the stripper bolts SB2 take up. This action breaks the connection between the molded part 12 and the solidified material in the sprue S and runner 10 at the gate opening OG.
  • the distance between the X-1 and X-2 plates is held and, as the platen continues to travel, the mold parts at parting line P2. Plate B will continue to separate from plate X-2 until stripper bolts SB1 take up.
  • the ejector plate EP makes contact with a fixed stop, forcing the ejector pin EJ to remain still while the Plate B continues to travel. This forces the molded parts 12 to be automatically ejected from their respective cavity.
  • plate X-1 is pulled away from Plate A.
  • the Plate X-1 was originally held in position by the solidified material in the sprue and runner channel which forms the shape of the sprue channel 5 having a bulge BU and a runner EA.
  • the bulge holds the solidified material 10 in the sprue bushing SBU when the plate X-2 starts away, allowing the sprue and runner to break at the gate OG.
  • the plate X-1 starts to travel it acts on the solidified material to pull it from the sprue channel.
  • the plate X-1 is slotted (not shown) so that after the solidified material is pulled from the channel it drops through the slot and out of the mold. The mold is reclosed by reversing the moving platen.
  • the injection nozzle valve N1 is brought into contact with the sprue bushing SBU. It is then opened by retracting pin P1 and softened resin is injected into the sprue channel defined by sprue bushing SBU where it initially starts to expand. Continued injection, however, fills and pressurizes the sprue channel, compressing the resin back towards its original state. At a certain pressure, the resin will begin to be injected through the small orifice gates OG leading to the mold cavities C where it again starts to expand. At the appropriate time, before each cavity C becomes completely filled, the nozzle valve N1 is shut off, stopping the flow of material to the sprue channel.
  • the rapid injection of material into the mold is of importance to the subsequent performance of the molded article as a closure for a liquid product container. If injection occurs too slowly, the initial portion of the resin entering the cavity will have time to expand, contact the relatively cool walls of the mold cavity and solidify into a rigid and dense outer skin before the remainder of the resin can enter the cavity. Continued injection after this dense outer skin has formed will set up a shear boundary layer within the article being molded between the still soft inner core and the rigid outer skin which results in a shift between the two portions. This shift breaks the material bond between the two distinct portions of the molded closure. Expanding gas will ultimately collect in the boundary layer surface and force the two segments of the closure apart, thereby creating large voids V immediately beneath the dense outer skin of the closure as illustrated in FIG. 7.
  • these voids would serve as spaces into which the dense outer skin of the article could deflect to avoid compression, thereby creating a longitudinal channel on the molded closure surface.
  • These longitudinal channels often become leakage paths between the molded closure and the container wall allowing substances into or out of the container. To avoid these leaks, it is necessary to eliminate the presence of the void spaces by completing the injection of resin material into the mold cavity prior to its expansion to form a rigid and dense outer skin.
  • the mold of FIG. 1 can be successfully utilized to achieve one object of the present invention, namely, a synthetic cork having an external appearance resembling natural cork.
  • the mold of FIG. 2 and the method of utilizing the same described hereinafter eliminates the creation of the aforementioned void spaces.
  • the mold of FIG. 2 works similarly to that of FIG. 1, except that there are far fewer parts since no solidified material must be ejected from the sprue and runner chamber.
  • a hot runner system is utilized instead.
  • the hot runner manifold HR and the hot tip bushings HTB, contain heaters (not shown) which prevent the plastic resin in the runner system EA from solidifying.
  • a lone parting line P1 exists between plats A and B since the X-1 and X-2 plates no longer exist.
  • mold cavity venting should be decreased to a minimum by reducing the clearances between the mold parts such as plates A and B which form the cavities C. This results in the cavities being temporarily pressurized by the entrance of the resin and subsequent displacement of the air so that the pressure, which served to restrict the expansion of the resin, is retained longer.
  • FIG. 9 which is an enlargement of a portion of FIG. 2, shows a shutoff pin SP in the retracted position and a single strand of unexpanded resinous material being introduced into the mold cavity.
  • valve pins SP of FIG. 2 are specially designed to fit into orifice gates OG of the mold and to perform the intended function of allowing sprueless molding.
  • the pins SP slide back and forth in the runner system EA, opening and closing the orifice gates.
  • the pins SP can be powered hydraulically or pneumatically, using a piston arrangement PN as shown in FIG. 2. Of additional importance is the fact that the sealing is accomplished at the very tip of the orifice gate OG to prevent any premature expansion of resin.
  • FIG. 2 mold a cycle is also initiated as in FIG. 1 by bringing the nozzle into contact with the hot runner manifold HR, opening the valves P1 and SP and injecting a measured amount of resin into each cavity. Again, before each cavity is completely filled, the valves are shutoff, allowing the material already in each cavity C to expand. However, because the shutoff pins in FIG. 2 are directly adjacent to the mold cavities at openings OG, no volume of softened, pressurized material remains in direct contact with the material being molded during the cooling and solidification period of the molded articles 12 which could cause the continued slow ingress of material into the cavities C. By the continued utilization of high injection pressure and minimum mold venting, it is possible, in this FIG. 2 design to complete and terminate the injection of material into each mold cavity proper prior to its expansion to form a skin. Thus, the creation of the undesirable void spaces is eliminated.
  • the remainder of the molding cycle is similar to other conventional injection molding operations, as described in the operation of the mold of FIG. 1.
  • the mold is opened and the solidified closure 12 is automatically ejected into water or similar refrigerated environment. Reclosing the mold initiates a repeat of the cycle. Closures molded by this method of FIG. 2, as shown in FIG. 8, have been found to exhibit none of the boundary layer-created voids of previous methods. Subsequent usage in liquid product containers has shown that leakage due to channels in the closure surface has ceased to be a problem. Furthermore, in the present molding method, no material is wasted by solidification in the sprue and runner chamber, thereby reducing molding costs.
  • the injection pressure is a function of the injection speed and thus these parameters are dependent upon each other.
  • the pressure within the mold is continually changing depending upon the injection pressure and/or injection speed, the size of the mold, the extent of the venting of the mold, and the like. Because of the many process variables which are mutually interdependent and continually changing it is difficult to generalize as to specific process parameters of the molding operation. However, knowing the desired properties of the plastic closure and a method which can be followed to achieve these results one can readily determine specific parameters for a given molding device possessing specific mold sizes and injection orifice sizes, such as mold temperatures, injection speeds and the like.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical And Physical Treatments For Wood And The Like (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Closures For Containers (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Laminated Bodies (AREA)
  • Steroid Compounds (AREA)
  • Acyclic And Carbocyclic Compounds In Medicinal Compositions (AREA)
  • Detergent Compositions (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Molding Of Porous Articles (AREA)
  • Adornments (AREA)
  • Plural Heterocyclic Compounds (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Sealing Material Composition (AREA)
US06/389,509 1982-06-17 1982-06-17 Synthetic articles having a cork-like appearance Expired - Lifetime US4507405A (en)

Priority Applications (27)

Application Number Priority Date Filing Date Title
US06/389,509 US4507405A (en) 1982-06-17 1982-06-17 Synthetic articles having a cork-like appearance
US06/458,775 US4522856A (en) 1982-06-17 1983-01-18 Synthetic articles having a cork-like appearance
IE834/83A IE54020B1 (en) 1982-06-17 1983-04-12 Synthetic articles having a cork-like appearance
NZ203931A NZ203931A (en) 1982-06-17 1983-04-19 Plastics composition resembling cork;container closures
CA000426157A CA1197045A (en) 1982-06-17 1983-04-19 Synthetic articles having a cork-like appearance
DE8383103815T DE3365407D1 (en) 1982-06-17 1983-04-20 Synthetic articles having a cork-like appearance
EP83103815A EP0097783B1 (en) 1982-06-17 1983-04-20 Synthetic articles having a cork-like appearance
AU13697/83A AU568491B2 (en) 1982-06-17 1983-04-20 Making synthetic corks
DE198383103815T DE97783T1 (de) 1982-06-17 1983-04-20 Kuenstliche gegenstaende mit korkaehnlichem aussehen.
AT83103815T ATE21523T1 (de) 1982-06-17 1983-04-20 Kuenstliche gegenstaende mit korkaehnlichem aussehen.
ES521817A ES521817A0 (es) 1982-06-17 1983-04-25 Un metodo para fabricar un cierre hecho de material resinoso termoplastico.
ZA832929A ZA832929B (en) 1982-06-17 1983-04-26 Synthetic articles having a cork-like appearance
MX197082A MX162483A (es) 1982-06-17 1983-04-27 Articulos sinteticos que tienen una apariencia similar al corcho
IL68517A IL68517A (en) 1982-06-17 1983-04-28 Synthetic articles having a cork-like appearance
PT76666A PT76666B (en) 1982-06-17 1983-05-10 Synthetic articles having a cork-like appearance
GR71375A GR78819B (ko) 1982-06-17 1983-05-17
KR1019830002241A KR860001373B1 (ko) 1982-06-17 1983-05-21 천연코르크마개와 같은 외관을 갖도록 하는 인조코르크 마개 및 그 제조방법
YU1139/83A YU43310B (en) 1982-06-17 1983-05-23 Method of manufacturing corks of a thermoplatic material looking like real cork
PL24227883A PL242278A1 (en) 1982-06-17 1983-05-31 Composition for forming of moulding having the appearance resembling this of natural cork
PL1983255942A PL144788B1 (en) 1982-06-17 1983-05-31 Method of making a closure of natural cork appearance
RO111153A RO88230B1 (ro) 1982-06-17 1983-06-02 Compozitie pentru articole tehnice
JP58105086A JPS596228A (ja) 1982-06-17 1983-06-14 コルク状外観を有する合成物品
HU832154A HU200349B (en) 1982-06-17 1983-06-16 Cork-like plastic stopper and composition and process for producing same
CS834368A CS258464B2 (en) 1982-06-17 1983-06-16 Profiled closure having good flexibility and elasticity and natural cork appearance and method of this closure's production
BG61361A BG46749A3 (en) 1982-06-17 1983-06-16 Cork- like composition
MA20038A MA19816A1 (fr) 1982-06-17 1983-06-16 Objets en matieres synthetiques ayant l'aspect du liege .
JP3289453A JPH0525307A (ja) 1982-06-17 1991-10-09 コルク状外観を有する合成物品を形成するための組成物

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US06/389,509 US4507405A (en) 1982-06-17 1982-06-17 Synthetic articles having a cork-like appearance

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US06/458,775 Division US4522856A (en) 1982-06-17 1983-01-18 Synthetic articles having a cork-like appearance

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US4507405A true US4507405A (en) 1985-03-26

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US06/389,509 Expired - Lifetime US4507405A (en) 1982-06-17 1982-06-17 Synthetic articles having a cork-like appearance
US06/458,775 Expired - Fee Related US4522856A (en) 1982-06-17 1983-01-18 Synthetic articles having a cork-like appearance

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US06/458,775 Expired - Fee Related US4522856A (en) 1982-06-17 1983-01-18 Synthetic articles having a cork-like appearance

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US (2) US4507405A (ko)
EP (1) EP0097783B1 (ko)
JP (2) JPS596228A (ko)
KR (1) KR860001373B1 (ko)
AT (1) ATE21523T1 (ko)
AU (1) AU568491B2 (ko)
BG (1) BG46749A3 (ko)
CA (1) CA1197045A (ko)
CS (1) CS258464B2 (ko)
DE (2) DE97783T1 (ko)
ES (1) ES521817A0 (ko)
GR (1) GR78819B (ko)
HU (1) HU200349B (ko)
IE (1) IE54020B1 (ko)
IL (1) IL68517A (ko)
MA (1) MA19816A1 (ko)
MX (1) MX162483A (ko)
NZ (1) NZ203931A (ko)
PL (2) PL144788B1 (ko)
PT (1) PT76666B (ko)
RO (1) RO88230B1 (ko)
YU (1) YU43310B (ko)
ZA (1) ZA832929B (ko)

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US5366675A (en) * 1994-03-02 1994-11-22 Needham Donald G Foamable polyethylene-based composition for rotational molding
US5496862A (en) * 1993-05-05 1996-03-05 Supreme Corq Molded styrene block copolymer closure for a wine container
US5904965A (en) * 1997-04-24 1999-05-18 Nomaco, Inc. Synthetic closure
WO2000015696A1 (en) * 1998-09-15 2000-03-23 Anthony Smith Australasia Pty. Ltd. Polymeric closure comprising foamed polyethylene or ethylene copolymer and a resilient compound
US6075063A (en) * 1997-02-22 2000-06-13 Moeller Plast Gmbh Method and foamable material for foaming or foam-coating components
AU721157B3 (en) * 1993-05-05 2000-06-22 Supreme Corq Molded closure for a liquid container
US6153275A (en) * 1996-08-13 2000-11-28 Neocork Technologies, Llc Multilayer synthetic stopper
USD435217S (en) * 1999-04-15 2000-12-19 Supreme Corq Synthetic cork for a liquid container
US20030102283A1 (en) * 2001-12-03 2003-06-05 Fox Robert W. Composite closure for removable insertion into wine or similar style bottle
US20040024073A1 (en) * 2000-03-15 2004-02-05 Ulrich Stieler Closure for bottle-like containers and method for production thereof
US6695997B2 (en) 1997-09-19 2004-02-24 Neocork Technologies, Llc Multilayer synthetic stopper
US20070202327A1 (en) * 2005-12-19 2007-08-30 Alberto Baban Synthetic cork with a natural cork appearance and method of making it
US20100117270A1 (en) * 2008-11-10 2010-05-13 Jan Alac Extrusion molding technique and synthetic stopper produced therefrom
KR101293154B1 (ko) 2010-07-29 2013-08-12 에코메이드(주) 에틸렌 비닐아세테이트와 유황분을 이용한 스펀지의 제조방법
US20160107345A1 (en) * 2007-08-16 2016-04-21 Maxi-Lift, Inc. Plastic injection molding and process

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US4756914A (en) * 1986-10-20 1988-07-12 Viskase Corporation Caramel-containing cellulosic article
US4984703A (en) * 1989-10-03 1991-01-15 Owens-Illinois Closure Inc. Plastic closure with compression molded sealing liner
US5047273A (en) * 1989-11-20 1991-09-10 Ernst Cox Julie C Plug structure
US5641573A (en) * 1993-11-19 1997-06-24 Lermer Packaging Corp. Printed synthetic resinous corks and method of making same
EP0684148B1 (en) * 1994-05-27 2003-03-12 Cubic Co., Ltd. Decorated shaped product
US6085923A (en) * 1996-08-13 2000-07-11 Neocork Technologies, Inc. Composite synthetic stopper
DE60014329D1 (de) * 1999-02-11 2004-11-04 C T E B Equipment Pty Ltd Vorrichtung und herstellungsverfahren von spritzgegossenen synthetischen verschlüssen, sowie hergestellter verschluss
KR100549574B1 (ko) * 1999-12-30 2006-02-08 주식회사 하이닉스반도체 유기 반사 방지막용 중합체 및 그의 제조방법
EP1145815B1 (en) * 2000-04-06 2004-05-12 Eduardo Ortiz Aycart A method of manufacturing stoppers for bottles and stoppers manufactured by the method
US20050233109A1 (en) * 2004-04-15 2005-10-20 Jeanine Hettinga Bottle closure
ITMI20042454A1 (it) * 2004-12-22 2005-03-22 Guizzardi Maria Morena Metodo per la marchiatura di tappi sintetici dispositivo per realizzare detto metodo e tappo sintetico
PT103591B (pt) * 2006-10-17 2010-03-23 Inst Superior Tecnico Processo de produção de corpos cilíndricos de material compósito de cortiça, destinados à produção de rolhas para vinhos de pressão, bem como as rolhas produzidas por este processo
EP2100824B1 (en) 2008-03-12 2011-05-04 Nestec S.A. Capsule with flow control and filtering member
WO2010083304A1 (en) * 2009-01-16 2010-07-22 R & B Marketing Corporation Plugs with dimensional tolerance absorbing hold-in surfaces
AP2013007325A0 (en) * 2011-05-13 2013-12-31 Ramchander Dorasamy Moulding method
ITTO20120956A1 (it) * 2012-10-30 2014-05-01 Menabreaz Ivaldi S R L Macchina per la fabbricazione di corpi di agglomerato di sughero, particolarmente tappi per l'impiego nel settore enologico.

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US4091136A (en) * 1976-05-17 1978-05-23 Shaw Plastics Corporation Synthetic cork-like material and method of making same
US4273880A (en) * 1978-07-22 1981-06-16 Bayer Aktiengesellschaft Foamed polyethylene films
US4255372A (en) * 1978-10-26 1981-03-10 Dynamit Nobel Aktiengesellschaft Process for the production of foam materials on polyolefin basis
US4363849A (en) * 1980-10-30 1982-12-14 The Coca-Cola Company Foamed thermoplastic resin cork having a natural cork-like appearance and a method of injection molding the cork

Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU721157B3 (en) * 1993-05-05 2000-06-22 Supreme Corq Molded closure for a liquid container
US5496862A (en) * 1993-05-05 1996-03-05 Supreme Corq Molded styrene block copolymer closure for a wine container
US5692629A (en) * 1993-05-05 1997-12-02 Supreme Corq Molded closure for a liquid container having printing thereon
US5710184A (en) * 1993-05-05 1998-01-20 Supreme Corq Molded styrene block copolymer closure for a liquid container
US5855287A (en) * 1993-05-05 1999-01-05 Supreme Corq, Inc. Synthetic closure for removable insertion into a wine bottle
US5366675A (en) * 1994-03-02 1994-11-22 Needham Donald G Foamable polyethylene-based composition for rotational molding
US6153275A (en) * 1996-08-13 2000-11-28 Neocork Technologies, Llc Multilayer synthetic stopper
US6248272B1 (en) 1996-08-13 2001-06-19 Neocork Technologies, Llc Multilayer synthetic stopper
US6075063A (en) * 1997-02-22 2000-06-13 Moeller Plast Gmbh Method and foamable material for foaming or foam-coating components
US6315938B1 (en) 1997-02-22 2001-11-13 Moeller Plast Gmbh Method for foaming or foam-coating components
US5904965A (en) * 1997-04-24 1999-05-18 Nomaco, Inc. Synthetic closure
US6695997B2 (en) 1997-09-19 2004-02-24 Neocork Technologies, Llc Multilayer synthetic stopper
US20040131819A1 (en) * 1997-09-19 2004-07-08 Stuart Yaniger Multilayer synthetic stopper
WO2000015696A1 (en) * 1998-09-15 2000-03-23 Anthony Smith Australasia Pty. Ltd. Polymeric closure comprising foamed polyethylene or ethylene copolymer and a resilient compound
US6608116B2 (en) 1998-09-15 2003-08-19 Anthony Smith Australia Pty Ltd Polymeric closure comprising foamed polyethylene or ethylene copolymer and a resilient compound
USD435217S (en) * 1999-04-15 2000-12-19 Supreme Corq Synthetic cork for a liquid container
US20040024073A1 (en) * 2000-03-15 2004-02-05 Ulrich Stieler Closure for bottle-like containers and method for production thereof
US20030102283A1 (en) * 2001-12-03 2003-06-05 Fox Robert W. Composite closure for removable insertion into wine or similar style bottle
US20070163989A1 (en) * 2001-12-03 2007-07-19 Fox Robert W Composite closure for removable insertion into a wine or similar style bottle
US20070202327A1 (en) * 2005-12-19 2007-08-30 Alberto Baban Synthetic cork with a natural cork appearance and method of making it
US20160107345A1 (en) * 2007-08-16 2016-04-21 Maxi-Lift, Inc. Plastic injection molding and process
US10836084B2 (en) * 2007-08-16 2020-11-17 Maxi-Lift, Inc. Plastic injection molding and process
US20100117270A1 (en) * 2008-11-10 2010-05-13 Jan Alac Extrusion molding technique and synthetic stopper produced therefrom
KR101293154B1 (ko) 2010-07-29 2013-08-12 에코메이드(주) 에틸렌 비닐아세테이트와 유황분을 이용한 스펀지의 제조방법

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IE54020B1 (en) 1989-05-10
YU113983A (en) 1986-02-28
RO88230B1 (ro) 1985-12-31
ZA832929B (en) 1984-06-27
AU568491B2 (en) 1988-01-07
HUT36017A (en) 1985-08-28
JPH0417975B2 (ko) 1992-03-26
PT76666A (en) 1983-06-01
YU43310B (en) 1989-06-30
KR840005168A (ko) 1984-11-05
DE3365407D1 (en) 1986-09-25
CS258464B2 (en) 1988-08-16
MA19816A1 (fr) 1983-12-31
GR78819B (ko) 1984-10-02
PL242278A1 (en) 1984-07-02
MX162483A (es) 1991-05-13
US4522856A (en) 1985-06-11
NZ203931A (en) 1986-04-11
RO88230A2 (ro) 1985-12-30
ATE21523T1 (de) 1986-09-15
BG46749A3 (en) 1990-02-15
KR860001373B1 (ko) 1986-09-17
PT76666B (en) 1986-01-10
JPH0543738B2 (ko) 1993-07-02
DE97783T1 (de) 1984-06-07
CS436883A2 (en) 1988-01-15
AU1369783A (en) 1983-12-22
JPS596228A (ja) 1984-01-13
IL68517A (en) 1986-09-30
JPH0525307A (ja) 1993-02-02
IE830834L (en) 1983-12-17
ES8404938A1 (es) 1984-05-16
EP0097783B1 (en) 1986-08-20
IL68517A0 (en) 1983-07-31
EP0097783A1 (en) 1984-01-11
ES521817A0 (es) 1984-05-16
HU200349B (en) 1990-05-28
PL144788B1 (en) 1988-07-30
CA1197045A (en) 1985-11-19

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